Marginal well monitoring and control systems and methods

ABSTRACT

The present invention relates to systems and methods for operating and controlling a well to keep the well alive so that the well will not need to be reworked to continue increased production. The system for operating the well generally includes a control and communications module having a well operation controller that connects with a plurality of sensors required to monitor and control the site, a plurality of sensors that measures pressure, amperage, tank level, and a server that stores and processes the information collected by the control and communications module.

CLAIM OF PRIORITY, IDENTIFICATION OF RELATED APPLICATIONS

This Non-Provisional Patent Application claims priority from US Provisional Patent Application No. 63/050,679 filed on 10 Jul. 2020 entitled MARGINAL WELL AUTOMATED CONTROL, to common inventor Conner, et al.

TECHNICAL FIELD

The present invention generally relates to natural resource production in marginally producing well. More specifically, the present invention relates to systems and methods for operating and controlling a well.

PROBLEM STATEMENT AND HISTORY Interpretation Considerations

This section describes technical field in detail and discusses problems encountered in the technical field. Therefore, statements in the section are not to be construed as prior art.

Discussion of History of the Problem

When oil prices drop, it can throw independent oil producers into a panic as they have to eliminate much of their labor force to try to stay in business. They also need to close off wells that are producing oil since the market price doesn't yield a profit if they were to sell their product.

When these wells are closed, there are problems that can occur. For one, drilling the well in the first place was an expensive operation. If that well is closed off long enough and the hole loses pressure, it can lead to having to “re-work” the hole again when prices stabilize. To avoid costly reworking, some operators will try to occasionally operate the well; both for the sake of keeping to hole integrity and to lubricate the parts on a pump jack itself.

For operators with no labor and lots of wells, it can be an overwhelming task to keep these wells “exercised” and some wells will just have to be sacrificed. Until now, there exist no apparatuses, systems, or methods that solve the aforesaid problems. Accordingly, the present invention provides systems, methods and devices that automate the control of the wells (or marginal wells) to decrease ongoing maintenance costs and increase production.

SUMMARY

In an aspect of the present invention, a system for controlling an operation of a well is disclosed. The system comprises a sensor one adapted to collect information regarding at least a first physical characteristic of a first well component to define a first physical characteristic reading value and a control and communications module adapted to control an operation of one or more well components via a well operation controller and communicate data via a transceiver to a server, the transceiver and the well operation controller being communicatively coupled.

The control and communications module is communicatively coupled to the sensor one that compares the first physical characteristic reading value collected for the first well component with a first physical characteristic predetermined value range, and if the first physical characteristic reading value is outside of the first physical characteristic predetermined value range, then the well operation controller adjusts power supplied to a first well control component, such that after the adjusted power is supplied, a new physical characteristic reading value is obtained that is within the first physical characteristic predetermined value range, to define a first compliant physical characteristic reading value.

The well operation controller has a memory for storing the first physical characteristic predetermined value range.

The system comprises the sensor one co-located with a first tank that stores a liquid extracted from the well, the sensor one being communicatively coupled to the control and communications module and the tank.

The system comprises a sensor two for monitoring an amperage supplied to the first well control component, the sensor two being communicatively coupled to the control and communications module.

The system comprises a wireless network coupled to the transceiver, the wireless network communicatively couples the control and communications module to the server such as remote server.

In various embodiments, the well is an oil well.

In various embodiments, the first well component is a wellhead.

In various embodiments, the first well component is a wellhead tubing.

In various embodiments, the first physical characteristic is a wellhead tubing pressure, a second physical characteristic is a tank level and a third physical characteristic is an amperage used by a prime mover.

In various embodiments, the first well control component is a prime mover motor.

In an aspect of the present invention, a method for controlling an operation of a well is disclosed. The method includes collecting information regarding at least a first physical characteristic of a first well component to define a first physical characteristic reading value at a sensor one. Further, the method includes receiving the first physical characteristic reading value at a control and communications module having a well operation controller. Furthermore, the method includes comparing the first physical characteristic reading value collected for the first well component with a first physical characteristic predetermined value range stored in a memory in the well operation controller, and then if the first physical characteristic reading value is outside of the first physical characteristic predetermined value range, adjusting power supplied to a first well control component, such that after the adjusted power is supplied, a new physical characteristic reading value is collected that is within the first physical characteristic predetermined value range, to define a first compliant physical characteristic reading value.

The method further comprising communicating the first physical characteristic reading value across a network to a server. The first physical characteristic reading value is a wellhead tubing pressure, a second physical characteristic reading value is a tank level and a third physical characteristic reading value is an amperage used by a prime mover.

BRIEF DESCRIPTION OF THE DRAWINGS

Various aspects of the invention and its embodiment are better understood by referring to the following detailed description. To understand the invention, the detailed description should be read in conjunction with the drawings.

FIG. 1 illustrates a control system for maintaining a properly functioning well.

FIG. 2 illustrates a block diagram for the control system.

FIG. 3 is a flow chart for a Well Operation Algorithm.

FIG. 4 illustrates a flow chart of a Pump Conditioning Algorithm.

DESCRIPTION OF AN EXEMPLARY PREFERRED EMBODIMENT Interpretation Considerations

While reading this section (Description of An Exemplary Preferred Embodiment, which describes the exemplary embodiment of the best mode of the invention, hereinafter referred to as “exemplary embodiment”), one should consider the exemplary embodiment as the best mode for practicing the invention during filing of the patent in accordance with the inventor's belief. As a person with ordinary skills in the art may recognize substantially equivalent structures or substantially equivalent acts to achieve the same results in the same manner, or in a dissimilar manner, the exemplary embodiment should not be interpreted as limiting the invention to one embodiment.

The discussion of a species (or a specific item) invokes the genus (the class of items) to which the species belongs as well as related species in this genus. Similarly, the recitation of a genus invokes the species known in the art. Furthermore, as technology develops, numerous additional alternatives to achieve an aspect of the invention may arise. Such advances are incorporated within their respective genus and should be recognized as being functionally equivalent or structurally equivalent to the aspect shown or described.

A function or an act should be interpreted as incorporating all modes of performing the function or act, unless otherwise explicitly stated. For instance, sheet drying may be performed through dry or wet heat application, or by using microwaves. Therefore, the use of the word “paper drying” invokes “dry heating” or “wet heating” and all other modes of this word and similar words such as “pressure heating”.

Unless explicitly stated otherwise, conjunctive words (such as “or”, “and”, “including”, or “comprising”) should be interpreted in the inclusive and not the exclusive sense.

As will be understood by those of the ordinary skill in the art, various structures and devices are depicted in the block diagram to not obscure the invention.

In the following discussion, acts with similar names are performed in similar manners, unless otherwise stated.

The foregoing discussions and definitions are provided for clarification purposes and are not limiting. Words and phrases are to be accorded their ordinary, plain meaning, unless indicated otherwise.

Description of the Drawings, a Preferred Embodiment

The present invention discloses systems and methods for operating and controlling a well (or marginal well) which includes a wireless controller (control and communications module) that connects with various sensors required to monitor and control a site, various sensors that measure pressure, amperage, tank level, for example and a server, cloud server for example, that stores and processes the information collected by the wireless controller for notification and reporting.

Advantageously, the present invention helps minimizing production and cost to keep the well alive so that the well will not need to be reworked to continue increased production. The present invention helps in controlling functioning of a pump when pressure falls below or goes above a controlled pressure value and limits the maximum time that the pump runs.

The terms “well” and “marginal well” may interchangeably be used throughout the present invention.

FIG. 1 illustrates a control system 100 for maintaining a properly functioning well 105. The control system 100 generally comprises a pump 110, a plurality of sensors 132, 134 and 136 (defined below), a prime mover motor control or pump motor control 148, a timer 138 and a wireless communication module 150. The well 105 is preferably an oil well, but may also be a natural gas well, injection well, or a water well, for example.

The pump 110 extracts fluid from the ground via a pumping operation. The pump 110 is typically a reciprocating pump, although other pump types are known to those of ordinary skill in the petroleum extraction arts, and these equivalents are incorporated in the present invention.

The pump 110 in FIG. 1 comprises a prime mover 112 having a prime mover motor 113, such as an electric motor, that drives a rotating component 116. Other prime movers include a gasoline motor, and equivalent alternatives known to those of skill in the art. Extracted fluid from the well is transferred to and stored in a tank 120, and in some embodiments a plurality of tanks is provided. In some advanced embodiments, tanks are each dedicated primarily to one of wastewater, brackish water, or petroleum. The fluid is transferred from the well 105 to the tank 120 using a wellhead pipe (or tubing or pipeline) 122 that connects a wellhead 114 of the well 105 to the tank 120.

The plurality of sensors includes, but not limited to, a sensor one 132, a sensor two 134 and a sensor three 136, which are used to monitor pump operation conditions. The operation conditions may include, but are not limited to, operation pressure conditions, electrical power consumption, operation temperature conditions, volumetric output of the well, flow rate of the fluid coming out of the well, tank fill level conditions, fluid type being extracted (or injected), and estimates of the composition of the fluid being extracted. Accordingly, common sensors implemented in the control system include a pressure sensor, an amperage meter, a temperature sensor, a flow meter, or a tank level sensor, for example.

The sensor one 132 may be present on or inside the tank 120 and preferably monitors the volume of fluid in the tank 120 (or tank level) and may detect the specific contents of the tank 120. The sensor two 134 is preferably located on the wellhead 114 to detect at least a wellhead tubing 112 pressure. The sensor three 136 is communicatively coupled to the prime mover 112, and preferably detects the average amperage consumed by the prime mover 112. Upon reading this disclosure, it will be readily apparent to those of skill in the petroleum arts that a variety of well conditions may be monitored with sensors, and monitoring of these conditions is well within the scope of the present invention.

The sensor one 132 is preferably implemented as a level gauge, a radio frequency sensor, a float sensor, a displacement sensor, a differential pressure sensor, for example. Specifically, in a preferred embodiment, the sensor one 132 is Dwyer Instruments SBLT2-10-40-ETFE submersible pressure sensor, or a Dwyer Instruments 628-07-GH-P1-E1-S1 ¼″ NPS pressure transmitter.

The sensor two 134 is preferably a pressure sensor that measures the wellhead tubing pressure from the wellhead 114 at the wellhead tubing 122. The sensor two 134 specifically measures a pressure in the wellhead tubing pressure, that increases as the liquid in the well rises. The sensor two 134 may be a load cell sensor, a flow sensor, a reflectometer sensor, or an accelerometer and sensor combination, for example. In one preferred embodiment, the sensor two 134 is Dwyer 626-15-GH-P1-E1-S1 1000 PSI 4-20 mA sensor.

The sensor three 136 is preferably an electrical power monitoring sensor that monitors current through and a voltage across the prime mover 112 to determine electrical power consumption by the prime mover 112. The sensor three 136 may also incorporate an ammeter, a voltmeter, a galvanometer, a temperature sensor, or an eddy current sensor, for example. Preferably, the sensor three 136 is Time Mark A257B 3-Phase Power Monitor.

The timer 138 is used to operate the prime mover for a preset period. It is controlled from a signal (or communication path or prime mover motor control) 148 to start the pump operating for up to a preset amount of time, and then power is removed from the prime mover, usually through activation of a contactor. The signal 148 may also turn the timer 138 off early, disconnecting power from the prime mover. The timer 138 may also be a Variable Frequency Drive or other Motor control device. Preferably, the timer 138 is an DEC RTE-B1AF20 Multifunction Analog Timer.

A control and communications module 150 comprises a well operation controller 156, a wireless communications transceiver 152 and a power source 154 (Readily apparent to those of skill in the arts). A preferred implementation for the power supply 154 is a Mean-Well HDR-15-24. One preferred control and communications module 150 is MeiTrack T633L or Digi Connect Sensor+ that incorporates all both the well operation controller 156 and the wireless communications transceiver 152. Likewise, an alternative implementation includes a separate wireless communications transceiver and well operation controller. A preferred well operation controller include a microcontroller, a microprocessor, or an environmentally resilient programmable logic controller, for example. One preferred well operation controller 156 is an Automation Direct Click PLC. One preferred wireless communication transceiver 152 is a Digi WR31.

The control and communications module 150 is communicatively coupled to the plurality of sensors 132, 134 and 136 via a wireless or wireline network. Specifically, the control and communications module 150 is coupled to the sensor one 132 using a first communication path 142, to the sensor two 134 using a second communication path 144 and to the sensor three 136 using a third communication path 146. The control and communications module 150 is communicatively coupled with the timer 138 using a communications path 148.

Examples of wireless communication paths include communication networks such as Wi-Fi, Cellular, Bluetooth, and Near Field Communication networks, for example. Likewise, examples of wireline communication paths include optical fiber, cables, or wires, for example.

The well operation controller 156 controls the operation of the pump 110 by controlling power supply to the prime mover 112. Among other things, the well operation controller 156 has a memory (known in the art) that is used for collecting data regarding the operation condition of the well 105. This data is collected from the plurality of sensors. Then the data may be passed “raw” or may be processed prior to some selected or altered data being transmitted to a server 220 such as a remote server (described below in reference to FIG. 2). This data transmission is accomplished via a wireless communications transceiver 152, part of the control and communications module 150.

In other words, the wireless communications transceiver 152 is used for transmitting information between the well operation controller 156 and the server 220. The wireless communications transceiver 152 may be a radio transceiver used on third generation protocol, long term evolution, fifth generation protocol, a wireless fidelity (Wi-FI), a private network or point-to-point transceiver, for example.

FIG. 2 illustrates a block diagram 200 for the control system 100 and should thus be read in conjunction with FIG. 1. It is understood by those of skill in the art that this block diagram further explains the relationships between components and expands upon them; as such it does not limit the scope of the present invention.

The control and communications module 150 transmits data about the operating condition of at least one well component via its transceiver 152 to the server 220 through a network 210, wireless network, for example. The network 210 also communicably couples the server 220 with an end user communication terminal 230. The end user communication terminal 230 is any electronic device that provides a user with data regarding the operation condition of a well component(s) and is preferably adapted for wireless communication. The user communication terminal 230 receives notifications about an unwanted operation condition, such as one that requires or would benefit from human intervention. Accordingly, the end user communication terminal 230 may be a mobile phone, a laptop, a pager, or a tablet computer, for example.

The server 220 may be a dedicated server located on the premises of an enterprise or may be a virtual cloud server. In one embodiment, the server 220 communicates across the network 210 via a transceiver 222 such as a wireless transceiver, for example. In alternative embodiment, the server 220 is coupled to the network via a wireline network, as is known to those of skill in an unrelated art, namely the telephone arts. Thus, the server 220 is able to communicate with the well operation controller 156.

The server 220 may comprise a processor for executing software code that performs operations as described below.

In one embodiment, the server 220 comprises a memory that stores a first operational threshold value. The first operational threshold value is in one embodiment a minimum wellhead tubing pressure. Accordingly, when a wellhead tubing pressure is detected that is lower than the pressure required for reliable well operation, the software executing on the processor detects this condition. The server may also comprise a memory or a database that stores data regarding the operational status or performance of each well component being monitored.

FIG. 3 is a flow chart for a Well Operation Algorithm 300. The Well Operation Algorithm 300 begins with a Monitor Act 310 in which the plurality of sensors is read for readings such as physical characteristics of an extracted fluid/gas, pressure, temperature, tank level, voltage and/or amperage. Alternatively, the Monitor Act 310 may comprise a ‘steady state’ where the Well Operation Algorithm 500 awaits the receipt of a reading from a sensor. Accordingly, data information is obtained regarding the operation of one or more well components.

The Monitor Act 310 is followed by a Processing Act 320. In the Processing Act 320, the data collected from the sensor(s) is locally compared to desired operation values for the monitored sensor being evaluated. For example, a detected wellhead tubing pressure is compared to desired wellhead tubing pressures which indicate that the well is “healthy.” Or the Tank Level from the sensor one 132 is too low, indicating the well pump cannot continue for the next period.

Next, a Determining Query 330 asks if the reading under evaluation (physical characteristic reading value) is in a desired range (physical characteristic predetermined value range), which indicates that the system being monitored by the sensor is in a reliable state. If the data indicates that the physical characteristic(s) are within the desired range, as indicated by the “Yes” path, then the Well Operation Algorithm 300 returns to the Monitor Act 310. If the data indicates that the physical characteristic(s) are outside of the desired range, then the Well Operation Algorithm 300 proceeds to a Send Commands Act 340.

In the Send Commands Act 340, control commands are sent to the control and communications module 150 that initiates or adjust the activity of the correct component of the well so that the physical characteristic(s) being monitored by the sensor(s) that generated the data is brought into the desired range of performance. This is sending a command to the pump motor control 148, which will turn the prime mover 112 off until either the wellhead tubing pressure is sufficient, or the tank level is low enough to allow new liquid to be pumped into the tank.

The Send Commands Act 340 is followed by a Control Confirmation Act 350. In the Control Confirmation Act 350, the Well Operation Algorithm 300 receives data indicating that the correct component is operating as desired to bring the monitored physical characteristic(s) into compliance. Next, in a Receive Confirmation Act 360, the Well Operation Algorithm 300 detects that the monitored physical characteristic(s) is in actual compliance, and thus returns the Well Operation Algorithm to the Monitor Act 310.

The Act 360 includes the step of redirecting the process flow to act 310, post receiving the confirmation about the control command implementation.

FIG. 4 illustrates a flow chart of a Pump Conditioning Algorithm 400. The Pump Conditioning Algorithm 400 begins with a Sensor Information Act 410. In the Sensor Information Act 410, data is collected from at least one sensor.

Next, in a Compare Query 420, the detected pressure in the wellhead tubing is compared to a range of wellhead tubing pressures indicating sufficient liquid in the well. If the detected pressure is outside the range of the desirable wellhead tubing pressures (the liquid level at the bottom of the well is too low), then the Pump Conditioning Algorithm 400 returns to the Sensor Information Act 410. If, however, the detected pressure is within the range of the acceptable wellhead tubing pressures indicating sufficient liquid level to the pump, then the Pump Conditioning Algorithm 400 proceeds to a Start Pump Act 430. In the Start Pump Act 430, the pump (or well pump) 110 is turned on through the signal 148.

Next, in a Run Time Act 440, the pump 110 is operated for a period of time determined to be sufficient to pump liquid from the well under normal operating conditions for the given wellhead tubing pressure. After the period elapses, the pump 110 is turned off. Then, in a Receive Information Act 450 the data produced by the sensor(s) is read and stored in a memory of the control and communications module 150.

Following the Receive Information Act 450, the information gathered by the sensor(s) is reported across the network 210 to the server 220 in a Report Information Act 460. Further, in a preferred embodiment, data regarding a detected tank level is reported to the server 220 for separate processing in a Report Tank Level Act 470. Of course, the reported tank level may be independent of or repetitive of the data transmitted in the Report Information Act 460.

For example, the Report Information Act 460 may report the amount of electrical power consumed by the pump operation, while the Report Tank Level Act 470 may report both the amount of fluid present in the tank and may provide additional tank-related data such as the condensate present in the tank. The reported values are used by the server to determine additional appropriate actions to take to raise the wellhead tubing pressure.

Then, the Pump Conditioning Algorithm 400 returns to the Sensor Information Act 410.

Although the invention has been described and illustrated with specific illustrative embodiments, it is not intended that the invention be limited to those illustrative embodiments. Those skilled in the art will recognize that variations and modifications can be made without departing from the spirit of the invention. Therefore, it is intended to include within the invention, all such variations and departures that fall within the scope of the appended claims and equivalents thereof. 

What is claimed is:
 1. A system for controlling an operation of a well, comprising: a sensor one adapted to collect information regarding at least a first physical characteristic of a first well component to define a first physical characteristic reading value; a control and communications module adapted to: control an operation of one or more well components via a well operation controller; and communicate data via a transceiver to a server, the transceiver and the well operation controller being communicatively coupled; the control and communications module being communicatively coupled to the sensor one; the well operation controller configured to: compare the first physical characteristic reading value collected for the first well component with a first physical characteristic predetermined value range, and if the first physical characteristic reading value is outside of the first physical characteristic predetermined value range, then the well operation controller adjusts power supplied to a first well control component, such that after the adjusted power is supplied, a new physical characteristic reading value is obtained that is within the first physical characteristic predetermined value range, to define a first compliant physical characteristic reading value.
 2. The system of claim 1, wherein the well is an oil well.
 3. The system of claim 1, wherein the first well component is a wellhead.
 4. The system of claim 1, wherein the first well component is a wellhead tubing.
 5. The system of claim 1, wherein the first physical characteristic is a wellhead tubing pressure.
 6. The system of claim 1, wherein a second physical characteristic is a tank level.
 7. The system of claim 1, wherein a third physical characteristic is an amperage used by a prime mover.
 8. The system of claim 1 further comprising a sensor two for monitoring an amperage supplied to the first well control component, the sensor two being communicatively coupled to the control and communications module.
 9. The system of claim 1, wherein the first well control component is a prime mover motor.
 10. The system of claim 1 further comprising the sensor one co-located with a first tank that stores a liquid extracted from the well, the sensor one being communicatively coupled to the control and communications module and the tank.
 11. The system of claim 1 further comprising a wireless network coupled to the transceiver, the wireless network communicatively couples the control and communications module to the server.
 12. The system of claim 1, wherein the server is a remote server.
 13. The system of claim 1, wherein the well operation controller has a memory for storing the first physical characteristic predetermined value range.
 14. A method for controlling an operation of a well, comprising: collecting, at a sensor one, information regarding at least a first physical characteristic of a first well component to define a first physical characteristic reading value; receiving, at a control and communications module having a well operation controller, the first physical characteristic reading value; comparing, in the well operation controller, the first physical characteristic reading value collected for the first well component with a first physical characteristic predetermined value range stored in a memory, and then if the first physical characteristic reading value is outside of the first physical characteristic predetermined value range, adjusting power supplied to a first well control component, such that after the adjusted power is supplied, a new physical characteristic reading value is collected that is within the first physical characteristic predetermined value range, to define a first compliant physical characteristic reading value.
 15. The method of claim 14, wherein the first physical characteristic reading value is a wellhead tubing pressure.
 16. The method of claim 14 further comprising communicating the first physical characteristic reading value across a network to a server.
 17. The method of claim 14 wherein a second physical characteristic reading value is a tank level.
 18. The method of claim 14 wherein a third physical characteristic reading value is an amperage used by a prime mover. 